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Elements and Performance Criteria

1. Interpret specifications and organise materials
   • The procedure for assembly/disassembly of structure is determined in order to plan equipment use
   • Appropriate jigs, fixtures or bracing methods are selected to ensure maintenance of contour/structural integrity during disassembly/assembly operations
   • All components and equipment are organised
2. Prepare aircraft or sub-assembly for structural disassembly
   • Structure is supported with appropriate jigs, fixtures or bracing, as required
   • Structural components are removed, as required, to provide access
3. Disassemble aircraft structure or sub-assembly
   • Aircraft standard practices are applied in the removal of structural hardware and fasteners while observing all relevant work health and safety (WHS) requirements, including the use of material safety data sheets (MSDS) and items of personal protective equipment (PPE)
   • Disassembled components are tagged, as required, to facilitate correct reassembly
4. Prepare components and tooling for assembly
   • Jigs and fixtures are set up to ensure accuracy of component assembly
   • Replacement component alignment is checked for conformance to specifications prior to fastener hole generation
   • Hole location/relocation is carried out in accordance with specification procedures and standard practices
   • Standard practices in hole generation sequencing are followed to ensure that assembly stress defects are not built in
   • Components are disassembled, cleaned, deburred and surface treatments applied prior to final assembly while observing all relevant WHS requirements, including the use of MSDS and items of PPE
5. Assemble aircraft structure or sub-assembly
   • Sealants and/or adhesives are selected and applied in accordance with assembly specifications or applicable documentation while observing all relevant WHS requirements, including the use of MSDS and items of PPE
   • Components are positioned and secured with appropriate temporary fastening devices for accurate assembly
   • Fasteners are selected and installed in accordance with assembly specifications or applicable manuals
6. Inspect completed assemblies
   • Assembled components are inspected to confirm dimensional accuracy and specifications are met
   • Checking or testing equipment is used, where appropriate, to ensure requirements are met
   • Aircraft mensuration is checked for compliance with applicable maintenance manuals, where necessary
   • Required documentation is completed and processed in accordance with standard enterprise procedures

Range Statement

This field allows for different work environments and conditions that may affect performance. Essential operating conditions that may be present (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) are included.
Scope of unit applies to:	Assembly of aircraft sub-assemblies or end items from detailed parts using jigs and fixtures Disassembly and reassembly of aircraft structure, such as wings, tailplanes or fuselage sections, using trestling, jigs and fixtures Replacement of major structural load carrying members, for example, skins, longerons, spars, frames and bulkheads
Assembly procedures include:	Drilling, reaming and counter-sinking Fitting of fasteners and rivets Application of adhesives and sealants Fitting of hardware Application of corrosion inhibitors and protective coatings
Assembly stress defects include:	Oil canning, buckling, contour misalignment and stress raisers
Procedures and requirements include:	Industry standard procedures specified by manufacturers, regulatory authorities or the enterprise

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Performance Evidence

Evidence required to demonstrate competency in this unit must be relevant to and satisfy all of the requirements of the elements and performance criteria under the specified conditions of assessment, and must include:

applying relevant WHS procedures, including the use of MSDS and applicable items of PPE

using approved maintenance documentation and aircraft publications relating to aircraft structural disassembly and assembly

correctly supporting the aircraft structure by jacking, trestling, bracing and/or jigging methods

safely handling heavy components during removal and assembly

identifying various aircraft metals/composite materials and their basic metallurgy properties by interpretation of markings, numbering systems or visual, chemical or mechanical means

handling and storing aircraft metal and composite components to industry standards

identifying aircraft structural assembly fasteners (metal and composite) by interpretation of markings, numbering systems, size, shape and colour

using appropriate hand tools and machines to remove and assemble aircraft structural components, parts, sections and skin, including riveting equipment, drilling equipment, aligning tools, reamers and material fasteners (grip pins)

applying correct removal and installation techniques for general and close tolerance fasteners (rivets, standard and oversize hilocks), including hole preparation and location techniques

performing aircraft alignment and mensuration checks

applying sealants and restoring aircraft structure surface finishes.

The underlying skills inherent in this unit should be transferable into other areas that require similar techniques.

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Knowledge Evidence

Evidence required to demonstrate competency in this unit must be relevant to and satisfy all of the requirements of the elements and performance criteria and include knowledge of:

aircraft construction principles, including the causes of structural fatigue and corrosion

describing the basic construction methods used to assemble:

fuselage (pressure and non-pressurised)

wings, vertical and horizontal stabilisers, rotary wing tail cones and pylons

engine nacelles/pylons

doors and windows, including seals, sealants and locking mechanisms

material specifications for aluminium alloys and steel alloys used in aircraft structure

composite cloths, matrix materials and adhesives

structural material identification by markings and numbering systems

material identification by chemical, electrical and mechanical methods

material storage requirements

hardware types and specifications

composite bonding methods

identification of hardware

sealants used in aircraft structure and their application and handling

chemical surface treatments

electroplating

paints and finishes

WHS precautions associated with repair of aircraft structure, including the safe handling of heavy components

MSDS

PPE.

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